Dough Rolling Method and Product

ABSTRACT

An improved dough-rolling product and method for rolling sheeted dough. The proposed invention comprises a dough-rolling method having a dough sheeter that cuts a dough sheet into preforms having a concave leading edge and convex trailing edge. A rolling curtain creates a rolled preform with the leading edge on the inside and the trailing edge on the outside. The rolled preform is cooked to produce a rolled snack product with consistent thickness throughout its length and a round outer flap.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a divisional application of co-pending U.S. patentapplication Ser. No. 13/666,650, entitled “Dough Rolling Apparatus,Method and Product,” filed Nov. 1, 2012, the technical disclosure ofwhich is hereby incorporated by reference in its entirety.

BACKGROUND

1. Technical Field

The present invention relates to an apparatus and method for forming arolled dough food product. Specifically, this invention relates to adough-rolling apparatus having a dough sheeter that produces doughpreforms with particular shape characteristics, which is rolled intorolled dough preforms.

2. Description of Related Art

Rolled products are found in many different food industries such ascroissants, wafer sticks, and frozen/stuffed taquitos. Many prior artprocesses have been developed to address the complexities of rollingeach of these products. For example, the croissant industry generallyutilizes a relative speed differential between two belts. Croissants aremade from relatively thick dough with a high degree of tackiness, whichmakes it fairly easy to manipulate. In contrast, the wafer stickindustry typically uses a batter that is drum dried, wound around amandrel at a 45-degree angle, and then cut into pieces.

In the snack food industry, however, the dough used typically comprisesone or more starches and/or flour, which dough is then thinly sheeted,cut into pieces, and then toasted, fried and/or baked. Typical doughtypes include, but are not limited to, the following: potato-, rice-,corn-, and wheat-based doughs. The dough used in such snack products,unlike the dough used in other food industries, is generally very thin,fragile, and difficult to manipulate. This makes typical rollingtechnology unacceptable for such an application. Additionally, theprocessing rates required in the snack food industry are very highrelative to other industries, making dough-rolling even more difficult.Consequently, a need exists for a dough-rolling apparatus and methodthat produces rolled snack products that are consistent in texture andflavor.

SUMMARY OF THE INVENTION

The proposed invention comprises a dough-rolling apparatus and methodthat produces rolled dough preforms and food products with a concaveleading edge rolled inside the preform/product and a concave trailingedge forming a rounded outer flap on the outside of the rolledpreform/product.

In one embodiment of the invention, an apparatus comprises a doughsheeter comprising a cutting pattern and orientation configured to cut adough sheet into dough preforms having a concave leading edge and aconvex trailing edge when said preforms are deposited on a sheetingconveyor; at least one rolling curtain draped upon the sheeting conveyorconfigured to roll said dough preforms into rolled dough preforms,wherein said concave leading edge is inside each said rolled doughpreform and wherein said convex trailing edge is outside each saidrolled dough preform, thereby forming a rounded outer flap on each saidpreform. In another embodiment, said cutting pattern comprises a firstpreform cutout with a concave leading edge which is congruent andcontiguous with at least a portion of a convex trailing edge of a secondpreform cutout adjacent to said first preform cutout. In yet anotherembodiment, said cutting pattern comprises at least one circumferentialrow of preform cutouts, wherein each said preform cutout comprises aconcave leading edge which is congruent and contiguous with at least aportion of an adjacent preform cutout.

In one embodiment of the invention a rolled snack food comprises aconcave leading edge rolled inside said snack food and a convex trailingedge forming a rounded flap outside said snack food. In anotherembodiment, the rolled snack food comprises a total moisture content byweight of less than about 3%.

In one embodiment of the invention, a method of making a rolled snackfood product comprises cutting a dough sheet into dough preforms,wherein each said preform comprises a concave side and a convex side;depositing said dough preforms onto a conveyor such that each saidconcave side is a leading edge and each said convex side is a trailingedge; rolling said dough preforms to produce rolled dough preforms,wherein each said concave leading edge is inside each said rolled doughpreform and wherein each said convex trailing edge is outside each saidrolled dough preform, thereby forming a rounded outer flap on saidpreform; and cooking said preform to produce said rolled snack foodproduct comprising less than 3% moisture by weight. In anotherembodiment, the method comprises toasting said preforms after saidrolling step and before said cooking step.

Additional features and benefits of the present invention will becomeapparent in the following written detailed description.

BRIEF DESCRIPTION OF THE DRAWINGS

The novel features believed characteristic of the invention are setforth in the appended claims. The invention itself, however, as well asa preferred mode of use, further objectives and advantages thereof, willbe best understood by reference to the following detailed description ofillustrative embodiments when read in conjunction with the accompanyingdrawings, wherein:

FIG. 1 is a perspective view of a dough-rolling apparatus in accordancewith one embodiment of the present invention;

FIG. 2 is a perspective view of a dough sheeter/cutter used in oneembodiment of the present invention;

FIG. 3 is a perspective view of a snack food piece in accordance withone embodiment of the present invention;

DETAILED DESCRIPTION

While the invention is described below with respect to a preferredembodiment, other embodiments are possible. The concepts disclosedherein apply to other systems for producing sheeted products.

FIG. 1 is a perspective view of a dough-rolling apparatus in accordancewith one embodiment of the present invention, and FIG. 2 is aperspective view of the dough sheeter/cutter used in accordance with oneembodiment of the present invention. The dough-rolling apparatus iscapable of rolling most varieties of doughs, including but not limitedto starch-, potato-, rice-, corn-, and wheat-based doughs, andcombinations thereof. At the front end of the apparatus is asheeter/cutter roller (sometimes referred to as a “sheeter”) 102, whichappears on the far right side of FIG. 1, and is shown in perspectiveview in FIG. 2. In a preferred embodiment, the sheeter 102 comprises anindustrial combination sheeter-and-cutter such as, but not limited to,an eight-row corn masa sheeter. In another embodiment, a separate doughpre-form cutter can instead be positioned downstream from a sheetingroller. In a preferred embodiment, the system is designed to roll a flatpre-forms 104 into cylinders 114, which are approximately two incheslong and ⅜ of an inch in diameter, as shown in FIG. 1. Note, however,that other embodiments and product sizes still fall within the scope ofthis invention.

Sheeted and cut pieces of dough (“pre-forms”) 104 are transported awayfrom the sheeting and cutting stage by a receiving conveyor 106. In apreferred embodiment, the conveyor is operated at a line speed higherthan the rotational speed of the sheeter 102 in order to create spacebetween the preforms 104. This receiving conveyor 106 may comprise anyfood-grade, durable, but flexible material able to withstand repeatedabrasion by dough-rolling curtains 122, 124. The sheeting conveyor 106preferably comprises a perforated or chain-link structure of a durablematerial such as stainless steel, carbon steel, or another type ofmetal, a ceramic, or an abrasion-resistant polymer-based substance. Theconveyor 106 is supported and conducted by several rollers. Thisconveyor 106 has a ramped section 108, which is an inclined launchsection immediately followed by a more gradually declining (or leveling)discharge section. The grade of the launch section and thedeclining/discharge section, and thus the steepness of the ramp peak,will vary depending on the line speed of the conveyor. At typicalproduction rates, however, the launch angle is preferably about 20 toabout 24 degrees from level, and the decline angle is preferably about 4to about 8 degrees from level.

The conveyor 106 is set in motion using a conveyor drive assembly 110,which typically includes a motor (electric or gas) for the propellingforce. A rolling unit 112 is positioned downstream from the sheeter 102and above the conveyor 106. The rolling unit 112 preferably comprisesseveral hanging mesh or chain curtains 122, 124 specifically selectedfor applying a desired amount of drag and weight onto the doughpre-forms 104. If desired, a lift-arm assembly 120 can also be includedfor quick removal and/or replacement of the rolling curtains 122, 124.

In operation, after dough is sheeted and cut into pre-forms 104, thepre-forms 104 are conveyed over the ramp of the ramped section 108,which then gradually levels or drops off to induce the leading edge ofeach pre-form 104 to lift off of the conveyor 106 as each pre-form 104crests over the ramp. A roll-initiating curtain (or “first hangingcurtain”) 122 catches the leading edge of each pre-form 104 as it passesunder the curtain 122, thereby causing each pre-form 104 to beginrolling back over itself. Thereafter, a roll-completing curtain (or“second hanging curtain”) 124 completes the rolling of the doughpre-forms 104. In a preferred embodiment, the rolled product is a cornmasa product and has: about 1.75 to about 2.25 wraps/rolls; a length ofabout 1.75 to about 2.25 inches; an outer diameter of about 0.32 toabout 0.40 inches; and an inner diameter of about 1/16ths to about3/16ths of an inch. Most preferably, the rolled product after fryinghas: 2 wraps/rolls; a length of 1.9 inches; an outer diameter of 0.36inch; and an inner diameter of about ⅛ths of an inch.

The shape of the preform used in accordance with the present inventionhas certain characteristics that allow it to be rolled into a cylinderthat, when toasted, baked and/or fried, produces a snack product that isimproved over prior art rolled snack food products. In one embodiment,the rolled preform of the present invention is cooked to a finalmoisture content of less than about 3% by weight, or in a preferredembodiment less than about 2% by weight, using one or a combination ofthe following unit cooking operations: baking, frying, impingementdrying, microwaving, infrared heating, or toasting. In a preferredembodiment, the rolled preform is toasted to substantially fix therolled shape before transferring the toasted preforms to subsequentcooking or drying operations, such as baking or frying.

As depicted in FIG. 1, the preform has a concave leading edge and aconvex trailing edge. In the embodiment depicted in FIG. 1, the preformshape somewhat resembles a quarter moon or crescent moon.

FIG. 2 depicts a perspective view of the sheeter/cutter roller used inaccordance with a preferred embodiment of the present invention. Asdepicted therein, each circumferential row of the roller is configuredto produce a row of dough preforms with a convex side and a concaveside. Moreover, the concave side of one preform is congruent with atleast a portion of the convex side of the preform immediately adjacentto it in the same row. Arranging the cutting pattern in this mannerallows practitioners of the present invention to minimize the generationof scrap, increase the productivity and production rate, and yet stillproduce preforms that yield improved rolled products, as describedbelow.

When preforms are provided with a leading edge of concave shape and atrailing edge of convex shape, and the preform is rolled with theleading edge forming the interior of the rolled product and the trailingedge forming the exterior of the rolled product, the rolled preform canthen be toasted, fried, baked or otherwise cooked to form a snack foodproduct with improved qualities. One reason the rolled product of thepresent invention is improved over the prior art is because there is amore consistent amount of dough present throughout the length of therolled product. When an oval or circular dough preform, which has aconvex leading edge and convex trailing edge, is rolled, it produces acenter portion with more layers of rolled dough, and thus a largeramount of dough, than portions of the rolled product closer to the endsof the rolled product. Such a rolled product will cook unevenly betweenthe center and edges, causing difficulties in quality control, includingmoisture and texture control.

Another reason the rolled product of the present invention isadvantageous is because it gives the rolled product the appearance of atraditional rolled product, such as a taco, but without the productconsistency problems presented by a rolled oval or circular doughpreform. Also, the appearance gives the rolled preform of the presentinvention an advantage over square, rectangular or other polygonalshaped preforms, which when rolled still have sharp corners and edgeswhich are less desirable to consumers. The lack of sharp corners alsohelps the preforms of the present invention release well from thesheeter/cutter, thereby improving overall rolling performance andreducing product defects.

Finally, by arranging the sheeter/cutter in the manner shown in FIG. 2,with the concave edge of each preform being congruent and coterminouswith at least a portion of the convex edge of the adjacent preform,practitioners of the present invention can see a capacity and throughputincrease of at least 5% to 10% over prior art cutters that produce ovalor circular preforms. The throughput increase is the result of reducedamount of scrap between preforms. The only scrap generated by thesheeter/cutter roller of the present invention is that found betweeneach circumferential row of preform cutters 204. By contrast, a round oroval preform cutter would produce significant scrap between adjacentsides of each preform. Scrap can be minimized by cutting the dough sheetinto triangles, squares, hexagons or other polygons with adjacent sides.However, such products will not have the desirable appearance of arolled taco made from a round or oval tortilla.

The shape of the preform used in accordance with the present inventionallows a practitioner to deliver a rolled snack food product with adesirable appearance (a round outer flap) and a consistent thicknessthroughout its length, all done with a preform that releases well fromthe cutter and produces less scrap than prior art processes that makerolled products with a round outer flap.

FIG. 3 is a perspective view of one embodiment of the rolled snack foodproduct 114 of the present invention. As depicted therein, the concaveleading edge 220 has been rolled inside 205 the sack food product, whilethe convex trailing edge 210 has been rolled outside 215 the snack foodproduct, forming a rounded outer flap.

While the invention has been particularly shown and described withreference to a preferred embodiment, it will be understood by thoseskilled in the art that various changes in form and detail may be madetherein without departing from the spirit and scope of the invention.

We claim:
 1. A rolled snack food comprising a concave leading edgerolled inside said snack food and a convex trailing edge forming arounded flap outside said snack food.
 2. The rolled snack food of claim1 further comprising a total moisture content by weight of less thanabout 3%.
 3. The rolled snack food of claim 1 further comprising amoisture content of less than about 2% by weight.
 4. A method of makinga rolled snack food product comprising: cutting a dough sheet into doughpreforms, wherein each said preform comprises a concave side and aconvex side; depositing said dough preforms onto a conveyor such thateach said concave side is a leading edge and each said convex side is atrailing edge; rolling said dough preforms to produce rolled doughpreforms, wherein each said concave leading edge is inside each saidrolled dough preform and wherein each said convex trailing edge isoutside each said rolled dough preform, thereby forming a rounded outerflap on said preform; cooking said preform to produce said rolled snackfood product comprising less than 3% moisture by weight.
 5. The methodof claim 4 further comprising toasting said preforms after said rollingstep and before said cooking step.
 6. The method of claim 4 furthercomprising cooking said preform to produce the rolled snack food productcomprising less than 2% moisture by weight.